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The official email newsletter of the PTO in North America Issue 17 November 2007

SPONSORS

WOODHEAD PROFIBUS IO

PROSOFT WIRELESS PROFIBUS

ENDRESS+HAUSER PROCESS INSTRUMENTS

YOUR AD
HERE

IN THIS ISSUE
.

EDGAR KUESTER: IN MEMORIAM

PNO BACKS WIRELESS COOPERATION TEAM
WORKSHOPS AND SEMINARS - UPDATE
PROFINET DEVELOPER WORKSHOP
CHIP PRICE REDUCTIONS SIGNAL ACCELERATION FOR PROFINET
PROFINET COOPERATION ANNOUNCED
ISA INVOLVEMENT
MORE THAN MY BLOG'S WORTH?
CASE STUDIES: BRAZILIAN SUGAR AND ALCOHOL UPGRADES; PROFINET HELPS TOBACCO PLANT; PROFIBUS SMOOTHS DIESEL ENGINE MANUFACTURE
WORLD NEWS: CHINA, GERMANY, CHINA/JAPAN/THAILAND, CZECHIA, SWITZERLAND

NEW PRODUCTS: INTERFACE CARDS, INTERBUS PROXIES, ULTRA TOOL, PROFIBUS GATEWAYS, PROCESS GATEWAY, OPC SERVER, MASS FLOW

 

EDGAR KUESTER: IN MEMORIAM

It is with great sadness that we report the passing of Edgar Kuester, Chairman of PI, the umbrella organization representing PROFIBUS and PROFINET around the world. Edgar, who was also Chairman of the PROFIBUS Nutzerorganisation in Germany, guided PROFIBUS to become the world's most successful fieldbus. His vision and openness were instrumental in establishing the worldwide network of Regional PI Associations (RPAs) which, with over 1400 member companies, underpins the success of PROFIBUS. In recent years his focus had turned to PROFINET and his strategic thinking was, until very recently, still being directed towards making PROFINET even more successful than PROFIBUS.

PTO Chairman and PI Deputy Chairman Mike Bryant, said: "The world of automation has lost one of its key figures, although many people may not recognize Edgar's name. That is due to Edgar's unselfish dedication to evolving what he saw as a better future for all automation users. This applied equally to multilaterally-supported projects such as the EDDL Cooperation Team and the FDI initiative as it did to PROFIBUS or PROFINET, although his role was often in the background where his calm, analytical and decisive manner helped overcome many an obstacle.

"Edgar had been ill for some time but, being Edgar, he did not want to tell anyone or burden anyone with his problem. He was a great mentor and personal friend, helping me to establish PTO and supporting us unwaveringly, despite the differences in culture that we faced from time to time. Until the end he wanted only to discuss the things we were doing to continue promoting PROFIBUS and PROFINET. His wishes were that the business he helped create should continue to run like he designed it. It is my intention to live up to that request. I would like to extend my sympathies to Angie, his widow, who often accompanied him when we met informally and who will remain for me a powerful link with Edgar's legacy."

In accordance with the bylaws of PI, Mike will assume the duties of Chairman until a formal successor is named and elected. An announcement about a new Deputy Chairman is expected shortly.


PNO BACKS WIRELESS COOPERATION TEAM: The PROFIBUS Nutzerorganisation (PNO), PTO's sister organization in Germany, is backing an "unprecedented" initiative aimed at driving forward wireless standards for automation. The Fieldbus Foundation (FF), HART Communication Foundation (HCF) and PNO, have formed a Wireless Cooperation Team (WCT) to collaborate on wireless technology in the manufacturing and process industries. The new project is modeled on the organization’s successful collaboration on Electronic Device Description Language (EDDL) and is another step towards delivering consistent functionality to end users.

The introduction of wireless technology into the manufacturing and process industries will require suppliers, end users, and international standards bodies to address technical issues related to wireless applications. FF, HART, and PNO are working together in the interest of establishing a common, open standard. The intent of the collaboration is to facilitate the acceptance of wireless technology.

The three organizations have agreed to develop a specification for a common interface to a wireless gateway. The organizations have also agreed to base their work on the WirelessHART™ technology of the HART Communication Foundation and the emerging ISA SP 100.11a standard. The project shall develop use cases, requirements and specifications for wireless communication with intelligent field devices in process measurement and control applications in the Automation Industries. The goal of the cooperative project is to create a common specification while ensuring complete compatibility with the existing wired versions of each participant’s technology.

As was done with their EDDL cooperation, the three organizations have also agreed to develop a common set of compliance guidelines for incorporation into their respective product registration processes.


WORKSHOPS AND SEMINARS - UPDATE: There's still time to attend one of our one day training classes, which continue into December before taking a well earned break until the New Year.The 2008 schedule is now available with over 20 free classes planned. More will likely be added; watch the website for updates. Full details here.

Special Note: attendees receive a certificate for 5.5 Professional Development Hours (PDH). And as a bonus, the PTO raffles a week-long Certified Network Engineer Class (a $2695 value) at each PROFIBUS and PROFINET event!

ALERT: A PROFItech certified PROFINET engineer class has been set for Detroit in January. Details here


PROFINET DEVELOPER WORKSHOP: The PTO's 2007 series of free PROFINET Developer Workshops reached its finale with a visit to Boston in October. Carl Henning, workshop leader commented: "Our goal has been to provide PROFINET developers with a wide range of technical information, including PROFINET vendor presentations, to help them select the best tools to use. We've managed to reach a much larger number of people than expected and from the results I can tell you that 2008 should see exciting PROFINET products emerging from several industry majors."

Among those supporting the events has been ARC Advisory Group whose Harry Forbes spoke about the growth potential of Industrial Ethernet. Exhibitors included: Hilscher North America, Inc., HMS Industrial Networks, Inc., IXXAT, Inc., Real Time Automation, Siemens Energy & Automation, Softing North America and Woodhead Industries.

UPDATE: Four Developer Workshops are already in the pipeline for 2008.

The workshops were entirely free of cost or obligation. Watch out for the 2008 workshops. Watch the PTO web site for details.


CHIP PRICE REDUCTIONS SIGNAL ACCELERATION FOR PROFINET: News that the price of the ERTEC Ethernet Controller for PROFINET has been reduced by 40% (in volume) is the best indicator yet that PROFINET is now chasing PROFIBUS up the global networking success ladder.

ERTEC, sometimes seen as an IRT-focused device for high end Motion Control applications, is actually an all-purpose chip for any PROFINET application. It has conventional ‘store and forward’ capability as well as the ‘cut through’ needed for IRT, and it also has enough processing power to include the PROFINET stack, and a modest application too.

This flexibility, plus the price drop, makes ERTEC a highly competitive option for almost any type of end device. Embedding ERTEC means one product type can meet a variety of applications across the real-time spectrum so in many cases the development of multiple product types is no longer necessary.

ERTEC is available in a 2-port version with the Ethernet PHY, and a 4-port PCI board-based version intended for motion controllers. Embedding a 2-port version in an end device means that devices can be 'daisy-chained' instead of ‘star connected’ like most Industrial Ethernet devices. This removes the need for external switches and restores the single-cable benefits of fieldbus. Both factors make a PROFINET network easier, simpler, faster and cheaper to install and operate than other Industrial Ethernet solutions. In time more than 90% of external network switches may be eliminated, believes PI. A side-effect will be that counting installed Industrial Ethernet nodes will require a different strategy.

There's an ever-widening availability of PROFINET-enabling components. Siemens, Softing, Hilscher and Woodhead are just some of the companies offering development hardware, software and chips. The PIC in North America can provide development help and of course the PTO's own series of Developers Workshops is a good source of information about technologies and supplier support.


PROFINET COOPERATION ANNOUNCED: ABB Automation and Phoenix Contact have agreed to work together on PROFINET for the process industries. Phoenix Contact-subsidiary KW Software will take lead role for the technical integration of PROFINET technology into ABB field devices. The common objective is to strengthen and to develop PROFINET as a global industrial standard within Process Automation (ABB) and Factory Automation (Phoenix Contact). Peter Wendt, chief R&D officer Control Products of ABB Automation said: “With Phoenix Contact as a partner we expect excellent opportunities to meet even better the current and future customer requirements of intelligent field devices”.


ISA INVOLVEMENT: PTO Executive Director Mike Bryant attended an ISA chapter meeting in Raleigh in October to present the case for PROFIBUS and PROFINET. Deputy Director Carl Henning will do similarly on November 13th when he visits the ISA's LA chapter. More info on that date here. PTO hopes to deliver further presentations to ISA chapters in the future. At ISA EXPO in October, Mike Aldridge and Carl provided an overview of PROFIBUS and PROFINET as one of the technical sessions. There were about 35-40 attendees. More about the EXPO here.


MORE THAN MY BLOGS WORTH?: Carl Henning recently received high praise indeed from Automation World's Gary Mintchell. FUD has been a recurring theme of Carl's PROFIblog and in a recent revival Gary responded with an item wondering why FUD is deemed so necessary by certain vendors. PROFIblog continues to cover topics of all types as Carl flexes his typing muscles in ever more interesting ways. His recent visit to Beiling for a PI meeting somehow morphed out of a PROFINET one day training event in Detroit, where more people than had registered turned up (113 actually) to confound Carl's unsophisticated algorithm for estimating how many lunches to order. Elsewhere he rants about never, ever, using a fieldbus. Isn't the truth always stranger than fiction?


CASE STUDIES

Read how PROFIBUS and PROFINET are helping end users be successful around the world:

BRAZILIAN SUGAR AND ALCOHOL UPGRADES: A new White Paper has been published here

PROFINET HELPS TOBACCO PLANT :
Founded in 1939, the Xuzhou Tobacco Factory, located in the eastern province of Jiangsu, is one of the largest cigarette factories in China with fixed assets of 1.7 billion RMB (around $125M) and an annual production yield of 0.5 million cartons of cigarettes. The company was interested in implementing an innovative automation solution that would offer the flexibility to produce a larger number of product variants. In addition, customer system requirements called for easy traceability of production processes and an overall reduction of production costs. Siemens provided a PROFINET-based solution which included 10 SIMATIC S7-400 CPUs with SIMATIC NET CP 443-1 Advanced Ethernet communication processors and over 60 SIMATIC ET 200S stations with integrated PROFINET interfaces. WinCC HMI stations with SIMATIC Panel PCs and CP 1616 were also installed. SCALANCE X-400 industrial switches form the backbone of the network. Using PROFINET CBA (Component Based Automation) whereby modules of automation not only provided fast engineering but also the necessary production flexibility. By shortening production duration and requirements, the new solution resulted in substantial cost reductions. The increased system flexibility offered by the modularity of the PROFINET CBA solution made faster production adaptation to market requirements possible. Moreover, the system now enables real-time recording of all aspects of the production processes.

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PROFIBUS SMOOTHS DIESEL ENGINE MANUFACTURE:
Cummins, the world's largest independent manufacturer of diesel engines, builds over 62,000 engines for customers in Europe, Middle East, Africa and the Far East in 2006, and employs 1,000 people at its Darlington, UK, plant. There are more than 2,000 possible engine variants and Cummins recently decided to upgrade a large part of their assembly and pressure test process.
Engines had previously been transported through the manufacturing process by a combination of overhead chain conveyor, powered floor conveyor and an AGV system. This was all replaced by an EMS (Electric Monorail System) during a two week shutdown in 2006. The EMS comprises 600 meters of overhead monorail, 50 carriers, 14 switchpoints, 3 lift units, 1 rotate unit, 34 assembly stations and 4 pressure test stations. There are a number of PROFIBUS DP networks in the system, providing communication to RFID devices, HMI operator panels, maintenance touch panels, LJU carrier controllers and distributed I/O. These networks are also used to interface between the S7-317DP PLC's which control the system. All fifty carriers have a Moby data tag attached. This stores an engine's build attributes and determines its route through the system. At each of the assembly and test stations there is a Moby SLG read/write device which communicates the engine data and operational status back to one of the S7-317DP PLC's controlling the system. There are three production pressure test lanes and one repair test lane. Each carrier has an onboard LJU controller which constantly reads an encoded rail to determine its position in the system. Status and Command words are received and sent to each carrier from the S7-317DP PLC again via PROFIBUS DP. There are six color touch panel HMI's on the line, used for pressure test control and display and for maintenance functions such as alarms and manual functions. At every assembly station an OP77A HMI panel allows the operator to raise and lower the engine to a suitable working position, to offload engines to the floor, to reload engines into the system and to release an engine to the next station when work is complete. When engines are offloaded or reloaded the RFID tag is updated to reflect its new status. The OP77A was chosen because of its PROFIBUS connectivity and also because of it's alphanumeric keypad, which is used to enter engine serial numbers. The rotate unit accepts engines from one of two input lanes and delivers them to one of two pressure test lanes. In the year since the system was installed, production rates have increased from 220 engines per day to 350 engines per day. The system was designed and built by Cleveland Systems Engineering Limited in co-operation with Trackfit Engineering Services, who designed and installed the supporting steelwork and mechanical elements.


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WORLD NEWS

CHINA: The Regional PI Associations (RPAs), which represent PROFIBUS and PROFINET in individual countries, met in Beijing in August for the 19th PI Meeting. The meeting agreed on the global marketing strategy and defined measures how to implement and achieve common goals. The Chinese RPA is celebrating its 10th anniversary this year. GERMANY: At this year’s SPS/IPC/DRIVES (November 27 to 29, 2007 in Nuremberg), PI and more than 50 member companies will demonstrate the power and breadth of PROFIBUS and PROFINET solutions. The theme - ‘PROFIBUS - Easy to Use’ - emphasizes the market leadership of PROFIBUS. Over 100 PROFINET products from more than 20 companies will demonstrate the continuing growth of PI’s important Industrial Ethernet technology. SPS/IPC/DRIVES 2007 Hall 6, Booth 210! CHINA/JAPAN/THAILAND: The PROFIBUS PA book by Christian Diedrich and Thomas Bangemann is now available in Chinese and Japanese. A Thai version will be published soon. The new books can be ordered directly from RPAs. German and English versions can be ordered here. CZECHIA: ANF DATA has gained accreditation as a PROFINET Certification Laboratory for Isochronous Real-Time (IRT) and PROFIdrive. ANF DATA has provided PROFINET services for customers around the world and since 2004 has helped many companies bring PROFINET products to market. SWITZERLAND: The PICC and PITC at the Bern University of Science in Burgdorf held their 4th Training Workshop for Certified PROFINET IO Network Engineers in August. The session was enhanced by additional practical exercises covering automatic topology detection and network management. The duration was also extended to 3 days.


 

NEW PRODUCTS

INTERFACE CARDS: Woodhead Industries announces the BradCommunications SST PCI two channel interface card for PROFIBUS, which allows a computer to connect to two independent PROFIBUS networks. The interface is a universal PCI bus format, supports both 3.3V & 5V and is PCI-X compatible.
Features include device configuration and diagnostics through FDT using commDTM, diagnostic LEDs for system status, watchdog timeout and communication status Applications include connecting computers running software applications such as Operator Interfaces, Human-Machine Interfaces, PC Control and network diagnostics to PROFIBUS.
The cards are also available for other computer bus formats. Woodhead Industries

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INTERBUS PROXIES: Phoenix Contact is now offering two more Interbus proxies for PROFINET, with copper and fiber optic technology. They combine a four-port switch based on the ERTEC 400 chip with an Interbus master. The switch can be used to implement various topologies. For example, it can implement the uplink to a higher-level control system or be connected in a linear structure in distributed applications in the field. Seamless access to Interbus devices via PROFINET is delivered so data exchange, diagnostics, and parameterization are carried out via the PROFINET protocol. The device can therefore be integrated into any control system with PROFINET functions and parameterized with the relevant programming tool. A PROFIBUS proxy with four-port switch is under development. Phoenix Contact

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ULTRA TOOL: A “giant leap forward” for PROFIBUS is claimed for ProfiTrace II and ProfiCore Ultra tools, which allow oscilloscope, busmonitoring and master activities to be carried out simultaneously via a USB connection. Technicians can now check and troubleshoot PROFIBUS networks with one software package and one piece of hardware. This results in an enormous reduction in equipment, weight, costs and training. The USB hardware (ProfiCore Ultra) is internally equipped with a high speed oscilloscope and able to capture bus signals running at 12 Mbps. Grid Connect : sales@gridconnect.com
or 630 245 1445

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PROFIBUS GATEWAYS: Softing has enhanced its industry-hardened single and multi-channel PROFIBUS gateways to allow access to all PROFIBUS gateway services, even without a Windows driver. This implies that non-Windows operator terminals or control computers with an Ethernet interface can act as DP or FMS masters - or even as DP slaves - without need for complicated porting procedures. For each channel, the gateways have a built-in server that executes the requested PROFIBUS services. The client computer uses a TCP/IP socket interface to exchange configuration and process data. The corresponding sample code in C is not operating-system-specific and is therefore easily ported. Softing

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PROCESS GATEWAY: Real Time Automation has designed a custom gateway box to gather data from up to 31 AquaSensors DataSticks using Modbus RTU communications and then feeding it to a PROFIBUS Master. A set of three DataSticks with Oxygen, Turbidity and pH sensors is organized on PROFIBUS as four slots. The first slot is for the gateway itself and the next three slots contain the Oxygen Sensor value and its temperature in the second slot, the Turbidity value and its temperature in the third slot, and the pH value and its temperature in the fourth slot. AquaSensors or 262-255-4459 or Real Time Automation - 414-453-5100

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OPC SERVER: The latest generation of Kepware's OPC server technology, KEPServerEX, was designed to allow users to quickly setup communications from equipment to control systems via a wide range of available plug-in device drivers and components. NI is now using KEPServerEX technology to create the new NI OPC Server. Automation users can now use the NI OPC Server to incorporate LabVIEW into their automation systems with concurrent connections to multiple PLCs. KEPWARE

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MASS FLOW : The FlexMASSter ST98 Flow Meter Series from Fluid Components International now meets PROFIBUS standards and has its own Device Type Manager (DTM) for use in large scale process and plant automation systems. The ST98 is a drop-in network replacement instrument for any similar PROFIBUS flow meter, and provides process flow and totalized flow data in minutes. FCI offers both single instrument and enterprise level DTM software to facilitate integration with PROFIBUS. FCI: +1 760 744 6950 or brownr@rbmarketing.com

 

 

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